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  1. D

    Engine swap

    Engine replacement checklist: https://www.jeepkj.com/threads/engine-replacement-checklist-kj-2002-2003-and-maybe-2004.80359/
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    2003 Liberty 3.7L sport, Reman engine from Tri-Star, p0304 code

    SUCCESS A lot of false leads, but I finally got all of the installation issues resolved. I have posted a simple engine replacement checklist here: https://www.jeepkj.com/threads/engine-replacement-checklist-kj-2002-2003-and-maybe-2004.80359/
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    Engine replacement checklist KJ 2002 2003 and maybe 2004

    This is an effort to share experience and knowledge related to replacing a Liberty 3.7L engine specifically for a 2003, but I am 99.7% confident that it also applies to 2002 and 2004. Theoretically, this checklist should also apply to *all* Chrysler PowerTech 3.7L V6 motors regardless of...
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    Engine runs rough after an hours worth of driving

    Have you solve your problem? If "yes" congrats. If "no" and you wish to continue the effort to solve the problem(s) read on. I have a 2003 3.7 4x4 and have just finished an engine replacement, that was complicated by old parts that exceeded life expectancy. You can pretty much count on 150K...
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    Misfire woes

    Sounds like you got it!
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    Misfire woes

    Note that PCMs are programmed very specifically to your vehicle build sheet, and the best way to make sure you get a matching PCM requires your VIN. If you opt to replace your PCM, strongly recommend getting a new one from Flagship 1 (highly reliable).
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    Misfire woes

    Please clarify, are you still throwing a misfire code? The moment a misfire code is thrown, the PCM will kill the signal to the problem cylinder until you reset the PCM. The cylinder will not fire until you either (a) clear the code with a scanner reset which is good for about 50 miles, or (b)...
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    Special Fuel Rail tool for 3.7L v6, 2002-2012

    Lol, ingenious! Greatest compliments!
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    Misfire woes

    That is great news. If the code pops again, please let me know. I replaced my PCM and it had no long term effect. When you replace the PCM you disconnect the battery, which effectively causes a hard reset of the PCM. My P0304 came back after about 120 miles. Subsequent hard resets might go...
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    Misfire woes

    Home made noid looks like this. Handy because you can simply plug the electrodes into the FI injector connector housing and tape the bulb to the top of the air intake where you can see it from the drivers seat when you start the KJ.
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    Special Fuel Rail tool for 3.7L v6, 2002-2012

    The coupling is a pressure-snap contraption, and you definitely need that Evercraft 776-9082. Prying at it with screwdrivers will wreck the coupling. You close the correct tool cuff around the tubing, slide the cuff down the tube inside of the coupling collar, and the coupling pops right off.
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    Misfire woes

    To clarify, did you physically swap your COPs or just rearrange them while they were still attached to their wires? The true test is to unplug, swap COP positions, plug in the correct wire per cyl, start car, drive it and see if the problem stays with the COP instead of the cyl. If it stays...
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    Special Fuel Rail tool for 3.7L v6, 2002-2012

    The Fuel Rail for *all* V6 3.7L Jeep Libertys (and pretty much anything that ever used the 3.7 V6 Powertech engine https://en.wikipedia.org/wiki/Chrysler_PowerTech_engine) requires a special tool to disconnect the main fuel line feeder hose that attaches at the rail. According to the Jeep...
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    Misfire woes

    I posted a detailed explanation of how to build/install (a) Fuel Injector and (b) Ignition Coil wiring harnesses from scratch. If you do this, do not use silicon wire... lesson learned was that the wire strands in silicon are very flexible... so use 18awg TXL stranded wire for the injector...
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    P0305 Cylinder #5 Missfire Cannot Remedy

    I am going through a 2003 3.7L overhaul, and I am plagued by a cyl 4 misfire. Ping me directly through this forum and we can start a dialogue about experience to date. Meanwhile use your scanner to review "Freeze Frame" info (state of the vehicle when the MIL triggered) and record it all. Use...
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    CEL - Cylinder Misfire

    I am going through a 2003 3.7L overhaul, and I am plagued by a cyl 4 misfire. Ping me directly through this forum and we can start a dialogue about experience to date. Meanwhile use your scanner to review "Freeze Frame" info (state of the vehicle when the MIL triggered) and record it all. Use...
  17. D

    CEL - Cylinder Misfire

    I am going through a 2003 3.7L overhaul, and I am plagued by a cyl 4 misfire. Ping me directly through this forum and we can start a dialogue about experience to date. Meanwhile use your scanner to review "Freeze Frame" info (state of the vehicle when the MIL triggered) and record it all. Use...
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    Coil 6 Insufficient Ionization, Multiple Cylinder Misfire, Fuel Injector 4 Circut/Open

    **** CORRECTION **** regarding "...there are actually 3 PCV valves on a 6 cyl..." in my reply above. There is only ***1 PCV***, but there are also 2 ***2 crankcase breathers*** that are found in the middle of two beather tubes that are defined in the manual as "PCV system hoses" (see page 25-18...
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    Engine swap

    "Tales from the trenches" or "Things to keep in mind if you are going to do a KJ engine swap": 1. If it's a KJ Liberty, it's not just an old vehicle. It's been obsolete for over 20 years. 2. Certain parts have a long, but not infinite life span: MAP, IACV, TPS, IAT, O2 sensors, manifold...
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    Engine swap

    Lol, didn't read it as criticism so no worries there. I'm going to add a little "tales from the trenches" commentary immediately following...

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